Electrical device hanger

ABSTRACT

An electrical device hanger is shown and described. The electrical device hanger can be used to suspend electrical devices at a user selected height and location so that conduit and electrical power can be run from another location to the device. This hanger is especially useful in open ceilings and reconstruction ceilings in commercial buildings. The hanger can be attached to the ceiling with a pair of threaded rods, a single threaded rod or s-hooks and jack chains. The hanger has clearance holes in the top and threaded holes in the bottom. The threaded rod passes through the clearance holes in the top and can be secured in the threaded holes in the bottom alone or can also be threaded to the device suspended. The device suspended from the hanger can also be affixed to the bottom of the hanger with fasteners in the threaded holes in the bottom. Alternatively, holes are provided in the top of the device hanger to utilize s-hooks and jack chain to attach the device hanger and the device to the ceiling. Conduit can then be affixed to attach the device to the power supply.

PRIORITY:

This application claims priority from Provisional Application for PatentSer. No. 61/188,510 with a filing date of Aug. 11, 2008.

FIELD

The present version of these embodiments relate generally to the fieldof devices used to hang electrical boxes and devices from the ceilingespecially in open ceilings and reconstruction ceilings of commercialbuildings.

BACKGROUND

These embodiments relate to devices used to hang electrical boxes andother electrical devices from the ceilings of buildings, and moreparticularly to a device that is simple to install and relatively cheapto manufacture.

There are many large and small commercial buildings all over. Typicallythese buildings have a high interior ceiling and roof; then lights,outlets, exit signs and other electrical devices and conduit are hungeither from the ceiling cross members or roof interior to apredetermined height and location. These hanging devices can be used forlighting and electrical power for the various devices that may be in useat the floor level such as equipment and machinery.

It generally would not be feasible to have the conduit and outlet boxes,lights and exit signs all run at the height of the ceiling or height oftheir use. This low height of the electrical power devices would requiretoo much care when moving and installing equipment on the floor of thebuilding and would just be difficult to move or rehabilitate a buildingwith all of the electrical connections, lights, exit signs all locatedat the working height. Consequently, the conduit, boxes and electricalsigns are attached to the main power at or nearer the ceiling to provideclearance for the movement of this heavy equipment on the floor andre-development or re-design of the space.

If the main power is running near the ceiling or roof interior, thepower to individual outlets, equipment and exit signs and other devicesmust be run from the ceiling or roof interior to the individuallocations where it is needed nearer the floor. This requires conduit andother electrical connections to connect the power from near the ceilingor roof interior to nearer the floor or user determined height andlocation. As a result, this equipment such as the outlets, exit signs,lighting and others must be suspended from the ceiling nearer the floorheight.

One of the primary methods of getting power to the near the floor heightor suspending electrical devices nearer the floor is to use threaded rodand framing channel or uni strut. This requires the installer to measurethe distance from the interior of the roof or cross members to theelevation that is necessary for the location of the outlet, the exitsign or electrical device. Once the distance from power source near theroof is known, the installer must cut threaded rod. The rod is attachedto the underside of the roof beams or other elevated interior roofstructure. There are many devices in the art to accomplish theattachment of the threaded rod to the underside of the roof or otheroverhead structure.

The threaded rod is then be attached to framing channel or uni strut atthe predetermined height and location nearer the floor. The device to besuspended from the framing channel must be attached to the framingchannel and the threaded rod thus suspends the device a predetermineddistance and location from the roof structure or cross members at thecorrect location and height relative to the floor.

If the installer is installing a device such as an outlet box, generallyone piece of framing channel would be affixed to the outlet box and twopieces of threaded rod would be attached near each of the ends of theframing channel. This works rather poorly especially if the device issuspended a great distance from the roof structure as these long rodswould cause the outlet box to swing back and forth and twist on thethreaded rods. In addition, the outlet box would require drilling toallow the conduit to attach to the outlet box.

This problem can be solved by using a first piece of framing channelnear the outlet (for example) with two pieces of threaded rod connectedto a second piece of framing channel located relatively close to theoutlet box and two longer pieces of threaded road from the second pieceof framing channel to the roof structure from which it is suspended.This configuration greatly complicates the installation of any suspendedelectrical device, greatly increasing time and costs of installation butdoes eliminate some of the swing and twist problems that can occur.

A great deal of measuring and cutting must be accomplished to suspendthe electrical device and deter the swing and twist that can result. Thelonger threaded rods must, in some of the background art, be attached tothe framing channel with fasteners such as nuts and bolts on both sidesof the second piece of framing channel to help prevent the device frommoving towards the ceiling. Likewise, some kind of fasteners must beused to attach the threaded rods to the first piece of framing channel.This requires much manual labor and time thereby increasing installationcosts. In addition to the threaded rod attachments, the actualelectrical device or connector must then be attached to the firstframing channel to ultimately suspend the device over the floor at thecorrect location and elevation. There is also the probability that thefasteners will fall to the floor requiring added labor time in acquiringreplacement hardware. The falling hardware can also pose a hazard toworkers or equipment below.

Obviously there are many different types of electrical devices thatcould be suspended from the first framing channel such as electricalboxes, conduit, lights and fixtures, exit signs, and many othersdependent upon the user's needs.

As one can appreciate, this process can be extremely time consuming andthereby expensive.

Applicant has developed a device that eliminates a large amount ofcutting, fitting and attaching of the framing channel or uni strut toaffix a device at the appropriate height and location over the floor.

The Applicant's device can accommodate a single threaded rod, a pair ofthreaded rods or a pair of and s-hooks and jack chain. The discloseddevice requires much less measuring and assembly time, eliminates theuni strut with associated fasteners and simplifies the attachment of theelectrical device to the applicants disclosed electrical device hanger.The device can thus be more easily located and installed and have theconduit which houses the wire that supplies power to the device affixed.For the foregoing reasons, there is a need for a new Electrical DeviceHanger.

These together with other goals of these embodiments, along with variousfeatures of novelty which characterize these embodiments, are pointedout with particularity in the remaining portions of this disclosure. Fora better understanding of these embodiments and the operatingadvantages, reference should be had to the accompanying drawings andattached descriptive matter.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a front view of one embodiment of the background art methodof attachment of a device at a preferred elevation and location.

FIG. 2 shows a side view of one embodiment of the background art methodof attachment of a device at a preferred elevation and location.

FIG. 3 shows a front view of one embodiment of the Applicant'selectrical device hanger attached to a device with dual threaded rods.

FIG. 4 shows a side view of one embodiment of the Applicant's electricaldevice hanger attached to a device with dual threaded rods.

FIG. 5 shows a top view of one embodiment of the Applicant's electricaldevice hanger.

FIG. 6 shows a bottom view of one embodiment of the Applicant'selectrical device hanger.

FIG. 7 shows a front view of one embodiment of the Applicant'selectrical device hanger.

FIG. 8 shows a front view of one embodiment of the Applicant'selectrical device hanger attached with a single threaded rod.

FIG. 9 shows a front view of one embodiment of the Applicant'selectrical device hanger attached with s-hooks and jack chain.

FIG. 10 shows a front view of one embodiment of the Applicant'selectrical hanger device.

FIG. 11 shows a side view of one embodiment of the Applicant'selectrical hanger device.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to the drawings in detail wherein like elements are indicatedby like numerals, there is shown in FIG. 1 a typical background artattachment of a first set of threaded rods 55 attached to a firstchannel 59. The threaded rods 55 are affixed to the first channel 59with fasteners 57. The device 12 is attached to the second channel 61with fasteners 57. A second set of threaded rods 55 attach first channel59 to second channel 61 with fasteners 57. Also shown is conduit 64through which electrical wire (not shown) is run which interconnects thepower supply located near the ceiling or other location and the device12 connected to hanger 14.

As can be appreciated, it is time consuming to affix the device 12 tothe hanger 14 as shown in FIGS. 1 & 2. Much cutting, measuring ofchannel and attaching of fasteners 57 must occur to hang the device 12as shown in this representation of the background art.

FIG. 2 shows a side view of the attachment of the hanger 14 of thebackground art to a device 12.

FIG. 3 shows the attachment of the applicant's hanger 14 to the device12. As can be seen from this figure, threaded rods 55 are insertedthrough second hole 36 and fourth hole 40 in the top 16 of the hanger14, FIG. 5. The threaded rods 55 extend to the bottom 18 where they areretained in the threads of sixth hole 43 and eighth hole 47. Thisembodiment also shows the threaded rods 55 securing the device 12 to theunderside of the bottom 18 of the hanger 14. Device 12 can havecorresponding threads matching the thread of the rods 55.

In comparing the background art to the configuration in FIG. 3, it canbe appreciated the simplicity of this device and cost savings frommaterials and cost savings in installation time.

FIG. 5 shows first hole 34 through fifth hole 41 in the top 16 of thehanger. The holes 34, 36, 38, 40 and 41 are clearance holes sized toallow the threaded rod 55 to pass through. First hole 34 and fifth hole41 in the top 16 of hanger 14 are clearance holes and are sized to allowthe passage of an S-hook 50 which can be attached to jack chain 51, FIG.9.

Applicant's figures do not show conduit 64 connecting the power supplyand the device 12, but it is understood that conduit and the attachmentof conduit from power supplies to electrical devices is known in theart. Any manner of attachment of the conduit from the power supply tothe device 12 could be utilized in combination with the applicant'shanger 14.

Second hole 36, third hole 38 and fourth hole 40 in the top 16 of hanger14 are sized to allow the threaded rod 55 to pass through withoutresistance but not large enough that the threaded rods 55 have anundesired amount of play. By example and in no way a limitation, second,third and fourth holes 36, 38 and 40 can be clearance holes for a ¼″threaded rod. Obviously other size threaded rods would require a largeror smaller clearance hole.

FIG. 7 shows that second hole 36 in the top 16 is collinear with sixthhole 43 in the bottom 18 of the hanger 14 along left center line 30.Likewise, third hole 38 in the top 16 is collinear with seventh hole 45in the bottom 18 of hanger 14 along center line 28. In the same fashion,fourth hole 40 is collinear with eighth hole 47 in the bottom 18 ofhanger 14 along right center line 32.

Sixth, seventh and eighth holes 43, 45, and 47 are threaded to match thethread of the threaded rods 55. This allows the threaded rods 55 to passthrough the holes in the top 16 of the hanger 14 and to attach and beretained in the holes in the bottom of the hanger 14 via the interactionof the threads of the rod 55 and the threads in holes 43, 45 and 47.

As explained above and shown in FIG. 3, device 12 can have holes andthreads that align with sixth hole 43 and eighth hole 47 such thatthreaded rods 55 can retain device 12 against or near the bottom 18 ofhanger 14.

FIG. 3 shows the attachment of the device 12 to the bottom 18 of thehanger 14 where a fastener 57 can be used to attach the device 12, inthis example, to the seventh hole 45. While this embodiment shows a nutattached to the fastener 57, it should be appreciated that the fastener57 shown could be attached to the seventh hole 45 by the interaction ofthe fastener 57 threads and the threads cut in the seventh hole 45.

The hanger 14 can be stamped from a sheet steel and have the holespunched and threaded and then have the ends welded together to form theshape of the hanger 14. Also notable are top angle 24 between the firstside 20 and the top 16, FIG. 3, and top angle 24 between the second side22 and the top 16. Top angle can be an angle greater than 90 degrees.

Also notable is bottom angle 26 between first side 20 and bottom 18 andbottom angle 26 between second side 22 and bottom 18. Bottom angle 26can be less than 90 degrees.

It should be understood that top angle 24 and bottom angle 26 could alsobe 90 degree angles or some combination of angles which would dependupon the manufacturing method. What is important in these embodiments isthat the center lines 28, 30, 32 align with their respectivecorresponding holes in the top 16 and the bottom 18 of hanger 14.

Hanger 14 could also be manufactured from materials other than sheetsteel such as other ferrous and non-ferrous materials. It is anticipatedthat the hanger 14 could be manufactured from an extrusion where“slices” are cut from the extrusion and the holes drilled and tapped inthe configuration as shown and described.

FIG. 8 shows a front view of applicant's hanger 14 attached to a device12. In this embodiment, the hanger 14 is attached to both the ceiling orupper attachment, not shown, and the device 12 by a single threaded rod55. The threaded rod 55 passes through the third hole 38 in the top 16of the hanger 14 and is affixed to seventh hole 45 in the bottom 18 ofhanger 14. As shown threaded rod 55 may also be attached to a matchingthreaded hole in the device 12. Threaded rod 55 may also have a nutattached affixing the device 12 to the hanger (not shown). FIG. 8 alsoshows fasteners 57 inserted from the device 12 and into holes 43, 47 toprovide additional strength to this junction. Conduit (not shown) isthen run from the power supply to the device 12 as is known in the art.

FIG. 9 shows an alternative attachment method of the hanger 14. In thisembodiment, a s-hook 50 is attached through second hole 36 and firsthole 34 in the top 16 of the hanger 14. A corresponding s-hook 50 isattached through fifth hole 41 and fourth hole 40 in the top 16 of thehanger 14. The s-hooks 50 are then attached to jack chain 51. The jackchain 51 is then attached to the ceiling or upper structure in theceiling, not shown. It should be understood that the s-hooks 50 could beinserted into the top 16 of the hanger 14 in the reverse, or insertedinto first hole 34 and second hole 36 and fourth hole 40 and fifth hole41 or the opposite of what is shown in this embodiment. Conduit (notshown) is run from the power supply to the device 12 as is known in theart.

While this embodiment shown does not eliminate the rotation and swingingof the device 12, some customers do request this manner of attachment.This embodiment can none the less save time during installation if thedevice 12 can be affixed directly to the bottom 18 of the hanger 14 withfasteners 57 in threaded sixth, seventh and eighth holes 43, 45, 47 orsome combination thereof.

FIG. 10 shows an alternative embodiment of the hanger 14. Hanger 14 isapproximately u-shaped. As can be seen, the configuration of the firstthru fifth holes 34, 36, 38, 40 and 41 are located in a top ledge 66 andsixth thru eighth holes 43, 45, 47 are located in a bottom ledge 68. Inthis embodiment there is a third side 23 which connects the top ledge 66to the bottom ledge 68. Top ledge 66 and bottom ledge 68 areapproximately parallel to one another and approximately perpendicular tothird side 23 thereby forming the u-shape.

Third side 23 can also have one cutout 70 or more cutouts 70. Thisembodiment shows two cutouts 70. Cutouts 70 are used to strengthenhanger 14 from twisting and also result in hanger 14 having less weight.Cutouts 70 could also take a different shape and there could be more orfewer cutouts 70 or even no cutouts 70 depending upon the user'sapplication of hanger 14.

In this embodiment, first thru fifth holes 34, 36, 38, 40, 41 areclearance holes for threaded rod 55 and sixth thru eighth holes 43, 45,47 are threaded matching the threads of threaded rod 55 as has beenpreviously explained. Likewise as has been previously discussed, thefirst and second holes 34, 36 and fourth and fifth holes 40, 41 in topledge 66 could be used to attach s-hooks 50, not shown.

The hanger 14 shown in FIGS. 10 and 11 provides an alternativeembodiment for hanging devices 12 as has ben previously described. Themanufacturing of hanger 14 in FIGS. 10 and 11 may also be cheaper againproviding significant benefits to devices shown in the background art.

It will now be apparent to those skilled in the art that otherembodiments, improvements, details and uses can be made consistent withthe letter and spirit of the foregoing disclosure and within the scopeof this application.

1. A hanger for suspending electrical devices, the hanger comprising: au-shaped frame with a top ledge, the top ledge having a first side and asecond side, the top ledge attached to a third side; the third sideattached to a bottom ledge, the bottom ledge having a first side and asecond side and approximately parallel to the top ledge; the top ledgeand bottom ledge approximately perpendicular to the third side; the topledge having a plurality of holes there thru, the holes approximatelyparallel to the third side; the bottom ledge having a plurality of holesthere thru, the holes approximately parallel to the third side; at leasttwo of the holes in the top ledge co-linear with two holes in the bottomledge; the bottom holes threaded; and the third side having a cutout. 2.The hanger of claim 1, wherein: three holes in the top ledge co-linearwith three holes in the bottom ledge.
 3. The hanger of claim 1, wherein:one hole in the top ledge located midway between the first side andsecond side.
 4. The hanger of claim 1, further comprising: the thirdside having two cutouts.
 5. A hanger for suspending electrical deviceson a threaded rod, the hanger comprising: a U-shaped frame having a topledge; the top ledge connected to a third side; the third side connectedto a bottom ledge; the third side having a first side and a second side;the top ledge having a first hole near one edge of the top ledge, athird hole located approximately in the center of the top ledge, asecond hole located between the first hole and the second hole, a fifthhole located near the second edge of the top ledge and a fourth holelocated between the third hole and the fifth hole; the bottom ledgehaving a sixth hole located near one edge and a seventh hole locatedapproximately in the center of the bottom ledge, an eighth holed locatednear the second edge of the bottom ledge; the second hole and the sixthhole located along a left center line extending through the top ledgeand through the bottom ledge; the third hole and the seventh holelocated along a center line extending through the top ledge and throughthe bottom ledge; and the fourth hole and the eighth hole located alonga right center line extending through the top ledge and through thebottom ledge.
 6. The hanger of claim 5, wherein: the first hole, secondhole, third hole, fourth hole and fifth hole are sized to allow thethreaded rod to pass there thru.
 7. The hanger of claim 5, wherein: thesixth hole, seventh hole and eighth hole are threaded to match thethreaded rod.
 8. The hanger of claim 5, further comprising: the thirdside has at least one cutout.
 9. A hanger for suspending electricaldevices on S-hooks attached to jack chains, the hanger comprising: aU-shaped frame having a top ledge; the top ledge connected to a thirdside; the third side connected to a bottom ledge; the third side havinga first side and a second side; the top ledge having a first hole nearone edge of the top ledge, a third hole located approximately in thecenter of the top ledge, a second hole located between the first holeand the second hole, a fifth hole located near the second edge of thetop ledge and a fourth hole located between the third hole and the fifthhole; the bottom ledge having a sixth hole located near one edge and aseventh hole located approximately in the center of the bottom ledge, aneighth holed located near the second edge of the bottom ledge; thesecond hole and the sixth hole located along a left center lineextending through the top ledge and through the bottom ledge; the thirdhole and the seventh hole located along a center line extending throughthe top ledge and through the bottom ledge; and the fourth hole and theeighth hole located along a right center line extending through the topledge and through the bottom ledge.
 10. The hanger of claim 9, wherein:the S-hook is attached through the second hole and the first hole of thetop ledge and the second S-hook is attached through the fifth hole andthe fourth hole of the top ledge.